Gas block for removing multiple impurities from the gas stream from an electrolyzer

Abstract

A gas block (10) for removing a plurality of impurities from a gas stream from an electrolyzer (1). The gas block (10) comprises at least one inlet (13), the at least one inlet configured to receive the gas stream from the electrolyzer, and at least two outlets (12, 14), the first outlet (12) configured to remove impurity liquid from the gas block, and the second outlet (14) configured to release the gas stream from the gas block. A first removal chamber (15) is located along the flow path of the gas stream between the at least one inlet and the first outlet, the first removal chamber removing liquid and / or vapor from the gas stream. A second removal chamber (16) is located along the flow path of the gas stream between the first removal chamber and the second outlet, the second removal chamber removing further impurities from the gas stream. The gas block is primarily used for purification of the hydrogen stream from the electrolyzer.

Description

[Technical Field]

[0001] The present invention relates to an improved gas block for processing a gas stream, for example a hydrogen gas stream, from an electrolyzer. [Background technology]

[0002] Hydrogen has many uses, ranging from energy storage to the production of fertilizer. Hydrogen can come from many sources. Some of these sources, such as fossil fuels, are undesirable for obvious reasons. Therefore, it is necessary to be able to produce hydrogen in a reliable and sustainable manner.

[0003] Electrolyzers are devices used to produce hydrogen and oxygen by splitting water. For example, surplus renewable energy can be used to power such devices, allowing the hydrogen to be used as a means of energy storage as opposed to batteries. Electrolyzers generally belong to one of three main technologies currently available: anion exchange membrane (AEM), proton exchange membrane (PEM), and liquid alkaline systems. Liquid alkaline systems are the most established technology, and PEM is somewhat more established. AEM electrolyzers are a relatively new technology. Other technologies, such as solid oxide electrolysis, are available.

[0004] AEM and PEM electrolysers rely on the transfer of ions from one half-cell to the other to produce hydrogen. AEM systems use hydroxide ions (OH - PEM systems rely on the transfer of hydrogen ions, H + It relies on the movement of

[0005] Certain forms of electrolysis, such as AEM electrolysis with dry cathodes, allow for the production of relatively pure hydrogen, but in some cases the hydrogen must be further processed to purify it before compression, use, or storage.

[0006] Currently, such purification means are separate units for different contaminants, e.g., there are dryers for removing water and other devices for removing other potential impurities such as amines from the decomposition membrane or other products resulting from the decomposition of upstream components. Summary of the Invention [Problem to be solved by the invention]

[0007] It is an object of the present invention to provide an improved integrated means for removing multiple impurities from a gas stream containing mostly hydrogen. [Means for solving the problem]

[0008] Aspects and embodiments of the invention are set out in the accompanying claims, and other aspects and embodiments of the invention are set out herein.

[0009] According to at least one embodiment described herein, a gas block for removing multiple impurities from a gas stream from an electrolytic device is provided, the gas block comprising: at least one inlet configured to receive the gas stream from the electrolytic device; and at least two outlets, wherein a first outlet is configured to remove liquid from the gas block and a second outlet is configured to release the gas stream from the gas block; a first removal chamber located along the gas stream flow path between the at least one inlet and the first outlet, the first removal chamber removing liquid and / or vapor from the gas stream; and a second removal chamber located along the gas stream flow path between the first removal chamber and the second outlet, the second removal chamber removing impurities from the gas stream (downstream of the first removal chamber).

[0010] According to another aspect described herein, there is provided a gas block for removing at least one impurity from a gas stream from an electrolyzer, the gas block comprising: at least one inlet configured to receive the gas stream from the electrolyzer; and at least one outlet for releasing the gas stream from the gas block, wherein a removal chamber is located along the gas stream flow path between the at least one inlet and the at least one outlet, the removal chamber removing at least one impurity (preferably liquid and / or vapor and / or decomposition products) from the gas stream. Thus, in this case, the first and second removal chambers of the above-described aspect may be integrated to form a single removal chamber without a boundary (such as a barrier, filter, interface, or membrane) between the first and second removal chambers.

[0011] Thus, advantageously, the present gas block provides an integrated means of removing multiple different impurities from the gas stream from the electrolyzer, as opposed to existing purification means that use separate units for different impurities.

[0012] Preferably, the first outlet of the gas block is located at a bottom portion of the gas block such that, in use, liquid is removed from the gas block via the first outlet under gravity.

[0013] Preferably, the at least one inlet is located in an upper portion of the gas block.

[0014] Preferably, the gas block comprises an additional removal chamber upstream of the first outlet for recombination of hydrogen and oxygen.

[0015] Alternatively, the gas block may comprise an additional removal chamber downstream of the first outlet for recombination of hydrogen and oxygen.

[0016] Preferably, at least one removal chamber, typically the first removal chamber, is coated with or surface treated to have either a hydrophobic or hydrophilic layer, preferably added in the form of a coating, removed in the form of laser ablation, or formed by another common process.

[0017] Preferably, the hydrophilic or hydrophobic layer has a maximum thickness of 5000 m 2 / g, preferably 1m 2 / g to 5000m 2 / g, more preferably 50m 2 / g and 4000m 2 / g. Higher surface areas may be desirable, but 2 / g to 10m 2 / g, or 1m 2 / g to 5m 2 / g, or 1m 2 It is envisioned that a surface area of ​​1000µm / g may also be advantageous, with the optimum surface area being determined by the desired hydrophilic or hydrophobic properties. Alternatively, a hydrophilic or hydrophobic layer may be present on the surface, depending on the desired effect achieved by the femtosecond laser. Such a surface may be formed on the wall itself, or on an insert placed in front of the wall. If an insert is desired, a first removal chamber should be provided with means adapted for inserting and removing the sheet insert.

[0018] In one embodiment, a coalescing filter is disposed in the first removal chamber. Alternatively, the coalescing filter (or other porous material) forms a boundary between the first and second chambers.

[0019] Preferably, the first removal chamber comprises a sponge-like or other structure that maximizes surface area to allow for heat exchange and / or to provide nucleation sites for condensation / droplet formation.

[0020] Preferably, the sponge-like structure comprises a plurality of voids, axial voids or capillaries for draining liquid, which voids, axial voids or capillaries may be provided using any known means, such as 3D printing.

[0021] In one embodiment, the first removal chamber comprises a groove in the interior wall of the chamber.

[0022] Preferably, the second removal chamber is adapted to contain a product or substance that removes decomposition products from the gas stream.

[0023] Preferably, the second removal chamber is an amine trap that comprises a product or substance that removes amines from the gas stream.

[0024] Preferably, the product or material that removes amines from the gas stream is a cation exchange resin.

[0025] Preferably, the second removal chamber is separated from the first removal chamber by a barrier (preferably a coalescing filter or membrane), the barrier having means for allowing gas flow from the first removal chamber to the second removal chamber.

[0026] Preferably, the barrier is permeable to gas flow so as to provide a means for transmitting the gas flow from the first removal chamber to the second removal chamber.

[0027] Preferably, the section of the barrier adjacent at least one of the inlet and / or second outlet is impermeable to gas flow.

[0028] Preferably, the gas block comprises a gas pressure regulator for regulating the pressure within the gas block and / or the pressure upstream of the electrolyzer. The gas pressure regulator is preferably located at the second outlet. The regulation can be set to a predetermined value, preferably less than 50 bar.

[0029] Preferably, the gas block further comprises a third outlet comprising a pressure relief valve configured to release gas from the gas block when a threshold pressure within the gas block is exceeded.

[0030] Preferably, the second removal chamber has a u-shaped section in the lower section of the wall.

[0031] Preferably, the second removal chamber is surrounded by the first removal chamber. It is also envisioned that the flow direction may be reversed, such that gas flows from the second chamber to the first chamber.

[0032] Preferably, the gas block is adapted to handle pressures in the range of 1 bar to 1000 bar, more preferably in the range of 2 bar to 100 bar, and even more preferably in the range between 20 bar and 50 bar.

[0033] Preferably, active cooling means are provided for part or all of the gas block.

[0034] Preferably, a heat exchanger is provided upstream of the at least one inlet. Alternatively, the heat exchanger may be located in the body or part of the body of the gas block. The body is the outer wall of the removal chamber.

[0035] Preferably, at least one inlet is connected to one or more electrolysers or other electrochemical devices, such as an electrochemical compressor.

[0036] Preferably, the electrolyzer is an AEM electrolyzer.

[0037] As used herein, the term "gas block" is used to refer to a device that includes an inlet and an outlet, which are openings that fluidly connect with a removal zone within the device for processing a gas stream containing hydrogen. A gas block may also be referred to as a gas manifold. A gas block may be tested, installed, and replaced independently of the rest of the system in which it is used.

[0038] As used herein, the term "gas stream" is used to refer to any stream containing reasonable traces of hydrogen gas with fluid impurities (including liquid or gaseous) such as, but not limited to, liquid water, water vapor, aerosols, oxygen, amines, etc.

[0039] As used herein, the term "liquid / vapor trap" is also referred to as a "water trap," with water being the most likely impurity to be removed.

[0040] As used herein, the terms "trap," "removal region," "removal chamber," and "removal zone" may be used interchangeably to define an area within the gas block where impurities are trapped or a zone where impurities are removed.

[0041] As used herein, the term "decomposition product trap" is used interchangeably with "amine trap," with amines being one example of a decomposition product that is trapped.

[0042] The inlet is generally envisioned to be in the top half of the gas block, although alternatively the inlet may be anywhere in the body of the gas block.

[0043] As used herein, the term "water" may be used interchangeably with "liquid" since, in the preferred embodiment, water is the most commonly present type of liquid. In other embodiments, such as CO electrolysis, an alcohol / water separation may be required.

[0044] While it is contemplated that there are two removal chambers, i.e., a first removal chamber for removing liquid / vapor and a second removal chamber for removing amine / decomposition products, it is contemplated that an additional removal chamber may be provided to remove impurity gases. In a preferred embodiment in which a gas block is connected to an electrolyzer, the predominant potential impurity is oxygen. Therefore, a recombination device or catalyst layer may be provided to remove oxygen.

[0045] Such a recombination device can take many forms, such as a catalyst-lined first region or a catalytically active substrate spanning the cross section of the first removal chamber. Alternatively, the recombination device can be upstream of the gas block, but connected to the gas block, or downstream of the gas block. Preferably, any recombination zone is upstream of the liquid / vapor removal chamber so that the produced water can be removed in a single stage in the liquid / vapor removal chamber. However, other means of removing water may be provided.

[0046] It is envisioned that water trapping (i.e., liquid / vapor removal chamber) can be achieved by a variety of approaches, including coating the interior of the first removal chamber with a hydrophobic or hydrophilic layer. Even more preferably, the surface area of ​​the removal chamber with a hydrophobic layer can be increased by a high surface area substrate, such as carbon cloth. The high surface area substrate has a surface area of ​​at least 5000 m. 2 / g, or 1m 2 / g to 5000m 2 / g or 50m 2 / g and 4000m 2 Alternatively, the high surface area substrate may have a surface area between 1000 m / g and 1000 m / g. 2 / g or at least 500m 2 / g to 5000m 2 / g range or 500m 2 / g to 2500m 2 It is envisioned that surface areas ranging up to 10 m / g may be acceptable. Higher surface areas may be desirable, but 2 / g or less than 5m 2 / g of surface area, or 1 m 2 It is envisioned that surface areas less than 1 / g may be advantageous, with the surface area being determined by the desired hydrophilic or hydrophobic properties. In embodiments of the present invention, the inner surface of the water trap (i.e., first removal chamber) may be provided with alternating stripes of hydrophobic coated and / or surface-treated substrates and uncoated substrates. These may be parallel or perpendicular to the flow path of the gas stream being treated. Other modifications, such as coalescing filters along the flow path, may be used to encourage droplet formation.

[0047] It is envisioned that the gas block may be at least partially 3D printed or otherwise fabricated such that a mesh-type structure is present in the flow path of the hydrogen-containing gas stream, said mesh-like structure acting as a coalescing filter.

[0048] Regardless of the method of manufacture, it is contemplated that the liquid / vapor removal chamber (i.e., the first removal chamber) may comprise a coalescing filter resembling a sponge-like structure. It is further contemplated that the sponge-like structure may comprise a plurality of axial voids in a substantially vertical orientation to allow liquid water to drain to and from the liquid outlet. Other orientations that facilitate liquid transmission to the liquid removal outlet are also contemplated, such as other flow channels, such as one or more grooves in the interior wall of the liquid removal chamber, that allow liquid transmission.

[0049] 3D printing is not intended to be a limiting factor, but as a manufacturing method, 3D printing allows for greater freedom and customization.

[0050] In a preferred embodiment, the filtration option selected in the first stage does not degrade so that water traps do not become a limiting factor in the life of the gas block.

[0051] The second removal chamber, i.e., the amine trap / decomposition product trap, is assumed to be a cation exchange resin. The upstream first removal chamber, i.e., the water trap, ensures that it is not alkaline or otherwise contains potentially interfering solutions such as KOH. NaOH or LiOH could reach and contaminate the second trap. As can be seen in the diagram, the configuration of the gas block with the amine trap, which utilizes gravity as another barrier to ensure that KOH does not reach the amine trap, also aids in this.

[0052] The amine trap resin can be regenerated, but in a preferred embodiment, the amine trap is sized to capture all amines present in the membranes of the electrolytic stack connected to the gas block. The amine removal material can be any suitable material, but is preferably, but not necessarily limited to, a cation exchange resin, such as a polystyrene backbone with sulfonic acid functional groups, such as commercially available Dowex® G26. In certain embodiments or use cases, additional and / or alternative anion exchange resins may be provided.

[0053] Although the gas block can be used with any gas stream including hydrogen, liquid and / or gaseous impurities, and amines, in a preferred embodiment the gas block is connected to an electrolyzer, more preferably an AEM electrolyzer, and even more preferably an AEM electrolyzer operating with a dry cathode.

[0054] While the present invention functions without a heat exchanger, it is envisioned that in a preferred embodiment, a heat exchanger, such as fins or other suitable means, or a heat sink, may be provided in the gas block itself between the outlet of the electrolyzer or other hydrogen source and the inlet of the gas block. The heat exchanger may be a coiled pipe and may have ambient cooling, forced air cooling, fins radiating from the pipe to encourage cooling, or any other suitable means for reducing the temperature of the stream being treated to encourage condensation of water or other vapors in the stream. The heat exchanger reduces the load on the water trap.

[0055] It is envisioned that a single gas block can process hydrogen from multiple sources, either through independent inlets or, more likely, through a single combined inlet.

[0056] While it is contemplated that the inlets and outlets may be located in either the top or bottom half as described, in preferred embodiments the inlets / outlets are configured to be in substantially the same plane at the distal end of the top or bottom gas block, the gas block being an elongated cylinder, rectangular prism, or prism of any shape. The inlets and outlets at the distal end utilize both gravity and maximize the flow path of the gas through the removal chamber, thereby maximizing the amount of impurities removed from the gas stream.

[0057] In one embodiment, the wall of the second removal chamber is solid, with only a single portion adapted to be porous to accommodate the gas stream. Such an embodiment may include a membrane separating the first and second removal chambers, or alternatively, a solid pillar with a porous disk. Means for separating the second (amine) removal chamber and its contents from the first (liquid / vapor) removal chamber, such as a membrane, a microporous layer, or another carbon cloth, may be used. Another example is a sintered metal with a metal membrane shell, the membrane having pore sizes between 100 nm and 200 nm, with a bulk pore volume of 5 to 10 microns or larger. Such features may be used to provide porous walls and a base for an amine removal trap.

[0058] It is also envisioned that the wall thickness of the second removal chamber may be varied, having thinner walls and a thicker base, which allows hydrogen to filter through the wall following the path of least resistance, and allowing water to exit the gas block through the thicker base by preferring to transition from larger pore size to smaller pore size.

[0059] In yet another embodiment, the second removal chamber (i.e., impurity trap) has at least one or more sections of porous wall at least in a portion of the bottom and / or side of the amine trap. It is contemplated that the wall closest to the inlet may be solid to prevent wet gas from entering the amine trap, while the wall further downstream may be porous to allow gas transmission from the first (liquid / vapor) removal chamber to the amine trap. It is also contemplated that the wall section closest to the amine trap outlet may be solid to prevent gas from bypassing the resin contained within the amine trap. In a preferred embodiment, a U-shaped section in the lower half or lower two-thirds of the wall may be porous.

[0060] It is envisaged that the gas block can function under a variety of pressures. Preferably, the gas block is adapted to be able to handle the gas stream output by the electrolyzer under pressure, the pressure being substantially 1 bar or greater than 1 bar, in the range of 2 bar to 100 bar, in the range of 10 bar to 50 bar, in the range between 30 bar and 40 bar, or substantially 35 bar.

[0061] It is envisioned that a recombination device may be provided in the gas block, upstream of the first inlet, or downstream of the outlet. Such a recombination device may comprise a catalytically active surface for the combination of hydrogen and oxygen. Such a reaction produces water that can be removed via the first (liquid removal) outlet, and therefore a preferred location is upstream of said outlet.

[0062] Because the gas block is intended to operate under elevated pressure, in preferred embodiments, safety check valves are provided to allow the exhaust of gas flow to prevent potentially problematic pressure buildup.

[0063] It is envisioned that the safety check valve may be predetermined and / or modified. It is envisioned that this will be between 101% and 200% operating pressure, or 105% to 150% operating pressure, or more preferably between 115% and 125% or between 140% and 150% operating pressure. When connected to an AEM electrolyzer, the operating pressure is preferably between 5 bar and 100 bar, more preferably between 20 bar and 50 bar, and even more preferably between 35 bar and 45 bar. In a preferred embodiment, the cooling is passive. However, it is envisioned that active cooling means, such as a fan, may be provided.

[0064] The invention described herein has the distinct advantage of providing an all-in-one, compact solution for treating hydrogen from electrolyzers prior to use, compression, or storage. However, the invention may be used to treat hydrogen gas streams other than electrolyzers as well. Similarly, the invention may be used to treat oxygen gas streams such as from electrolyzers, or any gaseous or multiphase effluent from an electrolyzer.

[0065] The present invention is not intended to be limited by the material of construction, and any suitable material may be used.

[0066] Any apparatus features described herein may also be provided as method features, and vice versa. Alternatively, means-plus-function features used herein may be expressed in terms of the corresponding structure of the same feature.

[0067] Any feature in one aspect of the invention may be applied to other aspects of the invention in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa. Furthermore, any, some, and / or all features in one aspect may be applied to any, some, and / or all features in any other aspect in any appropriate combination. It should also be understood that specific combinations of various features described and defined in any aspect of the invention may be implemented and / or provided and / or used independently.

[0068] Any feature of one aspect of the invention may be applied to other aspects of the invention in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa. Alternatively, means-plus-function features used herein may be expressed in terms of a corresponding structure for that feature, such as a suitably programmed processor and associated memory.

[0069] The present invention extends to methods, systems and apparatus substantially as herein described and / or shown with reference to the accompanying figures. [Brief explanation of the drawings]

[0070] One or more aspects will now be described, by way of example only, with reference to the accompanying drawings in which like reference numerals are used. [Figure 1] Figure 1 shows the gas block downstream of the electrolysis stack. [Figure 2] FIG. 2 is a cross-sectional view of a gas block according to a first embodiment of the present invention. [Figure 3] FIG. 3 is a cross-section of another gas block according to a second embodiment of the present invention. [Figure 4] FIG. 4 is a cross-section of another gas block according to a third embodiment of the present invention having a coalescing filter in the first removal chamber. [Figure 5] FIG. 5 is a cross-section of another gas block according to a fourth embodiment of the present invention, with the longitudinal axis at the first removal chamber. [Figure 6A] FIG. 6A shows a gas block according to a fifth embodiment of the present invention. [Figure 6B] FIG. 6B shows a gas block according to a fifth embodiment of the present invention. [Figure 6C] FIG. 6C shows a gas block according to a fifth embodiment of the present invention. [Figure 6D] FIG. 6D shows a gas block according to a fifth embodiment of the present invention. [Figure 7A] FIG. 7A shows the gas block of FIG. 6A with reverse flow. [Figure 7B] FIG. 7B shows the gas block of FIG. 6B with flow in the reverse direction. [Figure 7C] FIG. 7C shows the gas block of FIG. 6C with flow in the reverse direction. [Figure 7D] FIG. 7D shows the gas block of FIG. 6D with flow in the reverse direction. DETAILED DESCRIPTION OF THE INVENTION

[0071] 1, one can see an electrolysis stack 1 having a hydrogen outlet 2. A gas stream containing mostly hydrogen and some impurity gases such as water vapor and amines flows from the hydrogen outlet 2 to a heat exchanger coil 3, with additional optional cooling means such as a fan not shown.

[0072] As will be described below and shown in Figure 2, the gas flow enters the gas block 10 via inlet 11. The gas block has a liquid outlet 12, a safety check valve 13 set to release at a predetermined pressure, and an outlet 14 for treated hydrogen. Outlet 14 is above but downstream of the liquid outlet 12; the amine trap is not shown in this view. Inlet 11 and outlets 12, 13, and 14 are adapted to be connectable to pipes that introduce fluid into the gas block (i.e., the gas flow from the electrolysis stack) and remove fluid from the gas block (i.e., liquid out of liquid outlet 12 and gas out of pressure release outlet 13 and treated hydrogen outlet 14).

[0073] Referring now to Figure 2, a cross section of the gas block 10 of Figure 1 can be seen. From left to right on the top of the gas block 10, there is a first inlet 11 that takes in a gas stream containing hydrogen, in the middle there is a hydrogen outlet 14, and on the right there is an outlet to a safety check valve 13. A liquid / vapor outlet 12 is at the bottom of the gas block 10.

[0074] In use, a hydrogen-containing stream enters the gas block 10 via hydrogen inlet 11, as indicated by arrow 20a, which shows the flow path of the gas stream. The gas stream then flows through first removal chamber 15. In this example, first removal chamber 15 is a liquid / vapor removal chamber. Removal chamber 15 may be coated with a hydrophobic and / or hydrophilic material, a recombination catalyst, or other material. A recombination catalyst / device (not shown) enters first removal chamber 15 to remove any oxygen present, and the resulting liquid may exit via liquid trap 12.

[0075] When first removal chamber 15 is a liquid / vapor removal chamber, it includes features therein that encourage condensation of vapor impurities, thereby encouraging the formation of droplets so that the vapor impurities can be removed in liquid form. The features that encourage droplet formation can be a hydrophobic layer coating (not shown), and / or a high surface area substrate such as carbon cloth (also not shown), and / or stripes on the interior surface alternating between hydrophobic coated and uncoated substrates, and / or other surface treatments / coatings, such as laser-printed micron-sized holes or other patterns in the flow channels that allow selective condensation. The stripes can be parallel or perpendicular to the direction of flow of the gas stream transmitted through first removal chamber 15.

[0076] Liquid outlet 12 is intended to remove condensed water vapor and any impure KOH that has entered the gas block. By locating outlet 12 at the bottom of the gas block, gravity is utilized to aid removal, as liquid (including vapors that condensed in removal chamber 15) flows to the bottom of gas block 10 and exits through outlet 12. The flow path of liquid exiting through outlet 12 is indicated by arrow 22. A coalescing filter located in first removal chamber 15 or other device may also be used to aid liquid removal.

[0077] In normal operation, gas proceeds from first removal chamber 15 to enter second removal chamber 16. In this example, second removal chamber 16 is an amine trap / decomposition product trap that removes amines or other decomposition products. In FIG. 2 , the transition can be seen in spiral region 17, where a mesh, membrane, or other semi-permeable barrier is located to maintain the amine / decomposition product trapping compound inside second removal chamber 16. The mesh, membrane, or other semi-permeable barrier is located at the bottom of second removal chamber 16, at the boundary between second removal chamber 16 and first removal chamber 15. The amine trap is sized so that it can theoretically handle all potential amine decomposition from the attached electrochemical stack. In this example, the vertical wall separating first removal chamber 15 from second removal chamber 16 is impermeable to gas flow; therefore, gas flow can enter second removal chamber 16 only after traversing the length of first removal chamber 15. In this manner, a gas flow path extends through the first removal chamber 15 to promote condensation of vapor impurities in the first removal chamber 15 so that the impurities can be removed via the first outlet 12 .

[0078] The second removal chamber (in this example, the amine trap / decomposition product trap) contains a cation exchange resin (not shown) that functions as an amine removal material. Alternatively, the amine removal material may be any suitable material, but is preferably a cation exchange resin such as a polystyrene backbone with sulfonic acid functional groups, such as commercially available Dowex® G26.

[0079] A second outlet 14 is located above this chamber. The gas stream follows the flow path indicated by arrow 20b and passes through a second removal chamber 16. The gas, purified by passing through the first and second removal chambers, is released via the second outlet 14.

[0080] Safety check valve 13 is set to automatically open, allowing gas to be vented from gas block 10 at a predetermined threshold such that gas is released only if the pressure is too high for the upstream or downstream balance of plant. The flow path of gas being vented through check valve 13 is indicated by arrow 24.

[0081] A cross-section of an alternative embodiment of the present invention can be seen in Figure 3. Hydrogen gas and impurity gases enter gas block 10 via inlet 11 (A). The gas flow then passes through liquid removal chamber 15 (E), as indicated by arrow 20a. The liquid exits this embodiment via outlet 12 (D), as indicated by arrow 22. The gas flow proceeds to amine removal chamber 16 (F) for amine removal and, in normal use, exits via outlet 14 (B), as indicated by arrow 20b. Safety check valve 13 (C) is adapted to open only if the pressure exceeds a predetermined threshold, at which point the pressure is relieved by venting hydrogen through valve 13, as indicated by arrow 24.

[0082] 2, the liquid removal chamber may be coated in a similar manner and may optionally contain a recombination device / layer to remove any oxygen present. It is advantageous to place the recombination device in the first (liquid / vapor) removal chamber so that liquid produced as a result of any recombination can be removed via outlet 12. If the recombination device is placed downstream of outlet 12, an additional liquid removal outlet further downstream is required.

[0083] FIG. 4 shows a cross-sectional view of yet another alternative embodiment of the present invention. In this embodiment, hydrogen gas and impurity gases enter gas block 10 via inlet 11 to enter first removal chamber 15 (which is a liquid / vapor removal chamber). The liquid removal chamber in this embodiment includes a coalescing filter 26, indicated by cross-hatching. Specifically, first removal chamber 15 includes a mesh or sponge-like structure that functions as a coalescing filter. The mesh or sponge-like structure can be fabricated inside first removal chamber 15 by 3D printing both gas block 10 and the mesh or sponge-like structure.

[0084] Vapor impurities present in the gas stream entering gas block 10 condense to form a liquid in first removal chamber 15, which is separated from the gas components of the stream by coalescing filter 26. Under gravity, the liquid drains through filter 26 to outlet 12, where it is discharged as shown by arrow 22, to remove the liquid from the gas block.

[0085] The gas then travels from first removal chamber 15 into second removal chamber 16 through a hydrogen-permeable barrier layer 28 separating the two removal chambers. In this example, second removal chamber 16 is an amine trap / decomposition product trap that removes amines or other decomposition products, and therefore, second removal chamber 16 contains an amine removal material, such as a cation exchange resin (not shown), that is retained within second removal chamber 16 by barrier layer 28. The gas travels through second (amine) removal chamber 16 and exits via outlet 14, as indicated by arrow 20b.

[0086] Safety check valve 13 is adapted to open only when the pressure exceeds a predetermined threshold, at which time the pressure is relieved by venting hydrogen through valve 13, as indicated by arrow 24.

[0087] FIG. 5 shows a cross-sectional view of yet another alternative embodiment of the present invention. In this embodiment, hydrogen gas and impurity gases enter the gas block 10 through the inlet 11 to enter the first removal chamber 15 (which is a liquid / vapor removal chamber). The liquid removal chamber 15 in this embodiment includes a series of longitudinal axial voids or capillaries 29 that extend along the liquid removal chamber 15 in the same direction as the gas flow path. The capillaries 29 in this example are formed of a gas-permeable sponge-like structure. The capillaries encourage the liquid to bead up and condense into a liquid, which then drains down the capillaries 29 to the outlet 12 through which it is removed from the gas block 10. The capillaries can be fabricated within the first removal chamber 15 by 3D printing the gas block 10 and the capillaries.

[0088] In this embodiment, first removal chamber 15 and second removal chamber 16 (which is the amine / decomposition product removal chamber) are separated by hydrogen-permeable barrier 28 along most of the periphery of second removal chamber 16. However, near hydrogen inlet 11 and safety check valve 13, first removal chamber 15 and second removal chamber 16 are separated by hydrogen-impermeable walls 30a and 30b, respectively. Hydrogen permeates across capillaries 29 in the sponge-like material and across hydrogen-permeable barrier 28 into second removal chamber 16.

[0089] Near the hydrogen inlet 11, the impermeable wall 30a prevents any untreated hydrogen from entering the second (amine) removal chamber 16 almost immediately after entering the gas block 10, before vapor impurities condense in the first (liquid) removal chamber 15. In this way, the gas is forced to flow through the first (liquid) removal chamber 15 at least the length of the wall 30 before entering the second (amine) removal chamber 16. Similarly, the impermeable wall 30aensures that the hydrogen enters second removal chamber 16 at least approximately halfway along second removal chamber 16, and therefore ensures that the hydrogen passes through second removal chamber 16 at least the length of wall 30a before being released via outlet 14. Impermeable wall 30a therefore ensures a minimum level of purification of the gas in both removal chambers 15, 16.

[0090] An impermeable wall 30b near the safety check valve 13 prevents the hydrogen in the second removal chamber 16 from being exhausted when the valve 13 is opened to relieve pressure inside the gas block. In this way, raw hydrogen (but not processed hydrogen) can be exhausted through the valve 13 and redirected back to the inlet 11 for reprocessing in the gas block 10.

[0091] Although impermeable walls 30a and 30b are shown as extending approximately halfway along the length of second removal chamber 16, walls 30a and 30b may be shorter, for example, extending along only one-third of the length of second removal chamber 16. Similarly, walls 30a and 30b may be longer, for example, extending along the entire length of second removal chamber 16, leaving only a small portion of the bottom of second removal chamber 16 through which gas can enter second removal chamber 16, as in the embodiment described with reference to FIG.

[0092] Vapor impurities present in the gas stream entering gas block 10 condense to form liquid in first removal chamber 15. Under gravity, the liquid drains along capillary tube 29 to outlet 12, where it is vented as shown by arrow 22, to remove the liquid from the gas block. In this example, the interior walls of first removal chamber 15 are sloped to direct the liquid toward outlet 12. Gas passing through hydrogen-permeable barrier layer 28 into second (amine) removal chamber 16 passes through the amine removal material in second removal chamber 16 as shown by arrow 20b, and exits gas block 10 via outlet 14. Safety check valve 13 is adapted to open only if the pressure exceeds a predetermined threshold, at which point the pressure is relieved by venting hydrogen through valve 13 as shown by arrow 24.

[0093] 6A-6D show various views and cross sections of a gas block according to yet another alternative embodiment of the present invention. In this embodiment, a gas stream enters the gas block via inlet 11 and enters first removal chamber 15 (a liquid / vapor removal chamber). Vapor impurities present in the gas stream entering gas block 10 condense to form a liquid in first removal chamber 15, which is separated from the gas components of the stream. Under gravity, the liquid is drained through a filter (not shown) to outlet 12, where it is discharged. The gas stream then proceeds from first removal chamber 15 into second removal chamber 16 through a hydrogen-permeable barrier layer 28 separating the two removal chambers. In this example, second removal chamber 16 is an impurity (e.g., decomposition product / amine) removal trap. Gas proceeds through second removal chamber 16 and exits via outlet 14. Safety check valve 13 is adapted to open only if the pressure exceeds a predetermined threshold, at which point the pressure is relieved by venting hydrogen through valve 13.

[0094] Figures 7A to 7D show the same gas block 10 as Figures 6A to 6D, but with the inlet 11 and outlet 14 reversed and with a reversed flow, with the arrows indicating fluid flow from outlet 14 (which in this embodiment functions as an inlet) into second removal chamber 16, through barrier 28 and out from inlet 11 (which in this embodiment functions as an outlet) towards first removal chamber 15.

[0095] Not shown is a gas pressure regulator at the hydrogen outlet, which is set at a predetermined threshold to ensure that the pressure in the gas block and upstream of the gas block remains constant. This gas pressure regulator may be provided in the form of a valve at the inlet of the gas block (optionally a further valve at the outlet of the gas block) calibrated to open and close at a particular pressure threshold to allow fluid to enter and exit the gas block.

[0096] Alterations and Modifications It should be understood that the features disclosed in each of the gas block embodiments described with reference to each of Figures 2 to 5 may be combined. For example, at least the following modifications may be made: The coalescing filter 26 present in the first (liquid) removal chamber 15 of the gas block of FIG. 4 may also be incorporated into the first removal chamber of the gas block of FIG. 2 or FIG. ·figure 5 The capillary tube 29 present in the first (liquid) removal chamber 15 of the gas block of FIG. 2 may be incorporated into the first removal chamber of the gas block of FIG. 2 or FIG. The impermeable walls 30a, 30b and hydrogen-permeable barrier layer 28 present between the first (liquid) removal chamber 15 and the second (amine) removal chamber 16 of the gas block of Figures 4 and 5 may be incorporated between the removal chambers of the gas block of Figures 2, 3, or 4. Additionally, the length of the impermeable walls 30a, 30b may be varied as described. The locations of the various inlets (11) and outlets (12, 13, 14) of the gas blocks of Figures 2, 4 and 5 may be shifted to match the locations of the inlets and outlets of the gas block of Figure 2, respectively.

[0097] The present invention is not intended to be limited to the details of the foregoing embodiments. For example, the construction materials may be any suitable materials, and the construction methods may be any suitable methods. Shape is not necessarily intended to be a limiting factor, indicating concentric disks and donuts; a conical shape may be present in some or all of the gas block.

[0098] Additionally, the flow may contain other impurities not mentioned that are removed elsewhere or within the gas block.

[0099] It will be understood that the invention has been described above purely by way of example and that modifications in detail can be made within the scope of the invention.

[0100] Each feature disclosed in the description and (where appropriate) the claims and drawings may be provided independently or in any suitable combination.

[0101] Reference numerals appearing in the claims are by way of illustration only and shall have no limiting effect on the scope of the claims.

Claims

1. 1. A gas block for removing a plurality of impurities from a gas stream from an electrolyzer, comprising: at least one inlet configured to receive the gas stream from the electrolyzer; At least two exits; and a first outlet configured to remove liquid from the gas block; a second outlet configured to release the gas stream from the gas block; a first removal chamber located along a flow path of the gas stream between the at least one inlet and the first outlet; The first removal chamber removes impurity liquid and / or vapor from the gas stream; a second removal chamber located along the flow path of the gas stream between the first removal chamber and the second outlet; the second removal chamber removes additional impurities from the gas stream and is separated from the first removal chamber by a barrier; The barrier is means for conveying said gas stream from said first removal chamber to said second removal chamber; With a section of the barrier adjacent at least one of the inlets being impermeable to the gas stream; A gas block characterized by:

2. the first outlet is located at a bottom portion of the gas block such that, in use, liquid is removed from the gas block via the first outlet under gravity. The gas block of claim 1.

3. At least one of the inlets is located in an upper portion of the gas block.

3. The gas block according to claim 1 or 2.

4. The gas stream from the electrolysis device is Hydrogen and Oxygen and Including, The gas block comprises: an additional removal chamber upstream of said first outlet for recombination of said hydrogen and said oxygen; consisting of The gas block of claim 1.

5. The gas stream from the electrolysis device is Hydrogen and Oxygen and Including, The gas block comprises: an additional removal chamber downstream of said first outlet for recombination of said hydrogen and said oxygen; consisting of The gas block of claim 1.

6. the first removal chamber is coated with one of a hydrophobic layer or a hydrophilic layer; The gas block of claim 1.

7. The hydrophobic or hydrophilic layer has a maximum thickness of 5000 m ２ on a substrate having a surface area of ​​1 / g 7. The gas block of claim 6.

8. a coalescing filter disposed in the first removal chamber; The gas block of claim 1.

9. The first removal chamber comprises: Spongy structure, Equipped with The gas block of claim 1.

10. The sponge-like structure is a plurality of voids for draining liquid; Equipped with 10. The gas block of claim 9.

11. The first removal chamber comprises: a groove in the inner wall of the first removal chamber; Equipped with The gas block of claim 1.

12. Further impurities removed from the gas stream in the second removal chamber are decomposition products. The gas block of claim 1.

13. the second removal chamber is adapted to contain a product that removes the decomposition products from the gas stream; 13. The gas block of claim 12.

14. the second removal chamber is an amine trap with a product that removes amines; The gas block of claim 1.

15. The product of removing the amine is a cation exchange resin.

15. The gas block of claim 14.

16. the barrier is permeable to the gas stream so as to provide the means for transmitting the gas stream from the first removal chamber to the second removal chamber; The gas block of claim 1.

17. The section of the barrier adjacent to the second outlet is impermeable to the gas flow. The gas block of claim 1.

18. a third outlet comprising a pressure relief valve configured to release gas from the gas block when a threshold pressure within the gas block is exceeded; consisting of The gas block of claim 1.

19. a gas pressure regulator for regulating the pressure within the gas block and / or the pressure upstream of the gas block towards the electrolyzer or equivalent device; and the gas pressure regulator is disposed at the second outlet. The gas block of claim 1.

20. The second removal chamber comprises: A U-shaped section in the lower section of the wall, Equipped with The gas block of claim 1.

21. the second removal chamber is surrounded by the first removal chamber; The gas block of claim 1.

22. The gas block is adapted to handle pressures ranging from 2 bar to 100 bar. The gas block of claim 1.

23. Active cooling means are provided for some or all of the gas block. The gas block of claim 1.

24. a heat exchanger is provided upstream of at least one of said inlets; The gas block of claim 1.

25. At least one of the inlets is connected to one or more of the electrolyzers. The gas block of claim 1.

26. The electrolysis device is an AEM electrolysis device. The gas block of claim 1.

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